Starter Motor: Testing and Inspection

3UR-FE STARTING: STARTER: INSPECTION

INSPECTION

1. INSPECT STARTER ASSEMBLY
NOTE:
The following tests must be performed for no more than 5 seconds to prevent the coil from burning out.





(a) Perform pull-in test.
(1) Disconnect the lead wire from terminal C.
(2) Connect the battery to the magnet starter switch as shown in the illustration. Check that the clutch pinion gear moves outward.
If the clutch pinion gear does not move outward, replace the magnet starter switch assembly.





(b) Perform holding test.
(1) Disconnect the negative (-) terminal lead from terminal C with the condition specified in the pull-in test above being maintained. Check that the pinion gear remains out.
If the clutch pinion gear moves inward, replace the magnet starter switch assembly.





(c) Inspect clutch pinion gear return.
(1) Disconnect the negative (-) lead from the starter body. Check that the clutch pinion gear moves inward.
If the clutch pinion gear does not move inward, replace the magnet starter switch assembly.





(d) Perform the operation test without load.
(1) Connect the field coil wire to terminal C with the nut. Make sure that the lead is not grounded.
Torque: 6.5 Nm (66 kgf-cm, 57 in-lbf)
(2) Clamp the starter in a vise.
(3) Connect the battery and an ammeter to the starter as shown in the illustration.
(4) Check that the starter rotates smoothly and steadily while the pinion gear is moving out.
Then measure the current.
Standard current:
190 A or less at 11.5 V
If the result is not as specified, replace the starter assembly.
2. INSPECT STARTER ARMATURE ASSEMBLY
(a) Inspect the commutator for an open circuit.




(1) Measure the resistance according to the value(s) in the table below.
Standard Resistance:






If the result is not as specified, replace the starter armature assembly.
(b) Inspect the commutator for a short circuit.




(1) Measure the resistance according to the value(s) in the table below.
Standard Resistance:






If the result is not as specified, replace the starter armature assembly.
(c) Check the surface of the commutator for dirt and burns.
If the surface is dirty or burnt, correct it with sandpaper (No. 400) or a lathe.





(d) Using a vernier caliper, measure the commutator diameter.
Standard diameter:
35.0 mm (1.38 in.)
Minimum diameter:
34.0 mm (1.34 in.)
If the diameter is less than the minimum, replace the starter armature assembly.





(e) Using a dial indicator, measure the commutator runout.
Maximum commutator runout:
0.05 mm (0.00197 in.)
If the commutator runout is more than the maximum, correct it using a lathe.





(f) Measure the undercut depth of the commutator.
Standard undercut depth:
0.7 mm (0.0276 in.)
Minimum undercut depth:
0.2 mm (0.00787 in.)
If the undercut depth is less than the minimum, increase the depth using a hacksaw blade.
3. INSPECT BRUSH





(a) Using a vernier caliper, measure the brush length.
Standard length:
15.0 mm (0.591 in.)
Minimum length:
10.0 mm (0.394 in.)
If the brush length is less than the minimum, replace the starter brush holder assembly and yoke assembly.
4. INSPECT STARTER BRUSH HOLDER ASSEMBLY





(a) Inspect the insulation.
(1) Measure the resistance according to the value(s) in the table below.
Standard Resistance:






If the result is not as specified, replace the starter brush holder assembly.





(b) Inspect the load of the brush spring.
(1) Take a pull scale reading immediately after the brush spring separates from the brush.
Standard spring installed load:
21.5 to 27.5 N (2.2 to 2.8 kgf, 4.8 to 6.2 lbf)
Minimum spring installed load:
12.3 N (1.3 kgf, 2.8 lbf)
If the installed load is less than the minimum, replace the starter brush holder assembly.
5. INSPECT STARTER YOKE ASSEMBLY
(a) Inspect the resistance of the field coil.




(1) Measure the resistance according to the value(s) in the table below.
Standard Resistance:






If the result is not as specified, repair or replace the starter yoke assembly.




(2) Measure the resistance according to the value(s) in the table below.
Standard Resistance:






If the result is not as specified, repair or replace the starter yoke assembly.
6. INSPECT STARTER CENTER BEARING CLUTCH SUB-ASSEMBLY
(a) Check the gear teeth of the planetary gear and starter center bearing clutch for wear or damage.
If any planetary gear is damaged, replace the planetary gear assembly. If any gear of the starter center bearing clutch is damaged, replace the starter center bearing clutch sub-assembly.





(b) Check the movement of the clutch pinion gear.
(1) Rotate the clutch pinion gear clockwise, and check that it turns freely.
(2) Try to rotate the clutch pinion gear counterclockwise, and check that it locks.
If the clutch pinion gear cannot be turned clockwise smoothly, or does not lock in the counterclockwise direction, replace the starter center bearing clutch sub-assembly.
7. INSPECT MAGNET STARTER SWITCH ASSEMBLY





(a) Inspect the pull-in coil.
(1) Measure the resistance according to the value(s) in the table below.
Standard Resistance:






If the result is not as specified, replace the magnet starter switch assembly.





(b) Inspect the holding coil.
(1) Measure the resistance according to the value(s) in the table below.
Standard Resistance:






If the result is not as specified, replace the magnet starter switch assembly.